Heat exchanger and turbulator for the same

ABSTRACT

Disclosed are a heat exchanger and a turbulator for the same. The heat exchanger is integrally manufactured in a novel structure with a desirable size, so that the productivity can be improved and the flow resistance of the fluid can be minimized. The turbulator for a heat exchanger includes a plurality of crests and a plurality of valleys that are repeatedly formed, and a plurality of bent ends formed on front and rear surfaces of each crest and inwardly bent while being repeatedly alternated in a direction along which the crest and the valley are repeatedly formed. A portion of each bent end is inclined left or right to form a through hole perforated in the direction along which the crest and the valley are repeatedly formed so that the fluid passes through the through hole.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a heat exchanger and a turbulator for the same, in which the turbulator is integrally manufactured with a desirable size, so that fluid flow resistance can be minimized and the productivity can be improved.

2. Description of the Related Art

In general, a heat exchanger is a device to cool combustion heat and heat emitted when a fluid or air is compressed, or heat emitted from a rotational body.

In other words, the heat exchanger has been employed to all application fields in which heat must be cooled or a temperature must be increased.

In particular, in a heat exchanger according to the related art, a turbulator, which is separately manufactured, is interposed between heat exchange plates through which air and cooling water or oil pass while crossing each other, so that the air, the cooling water or the oil passing through each heat exchanging plate is turbulated. Accordingly, the heat exchange performance between air and the cooling water or between air and oil can be more improved.

In the case of an intercooler of the heat exchanger, after cooling air supercharged by an impeller, the cooled air is supplied to an engine, thereby preventing knocking and the degradation of charging efficiency caused by the increase of the air density and the reduction of an air ratio according to the temperature increase of the supercharged air.

In the case of an oil cooler of the heat exchanger, after cooling heat of fluid generated from an engine or a transmission, or during the hydraulic operation to a desired temperature by a heat exchanger, the fluid is circulated to functional parts so that performance of the engine or the transmission can be maintained.

In addition, the heat exchanger has been extensively used in a heat exchanging device field using a fluid. In particular, when manufacturing a large-scale heat exchanger, a turbulator, which is integrally manufactured to reduce fluid resistance, has been required.

The turbulator has been disclosed in U.S. Pat. No. 6,675,878 and Korean Unexamined Utility Model Publication No. 2008-6506. FIG. 1 is a view showing a turbulator according to the related art.

As recognized through the patent and the publication, a turbulator 20 according to the related art includes a plurality of crests 21 and a plurality of valleys 22 that are repeatedly formed, and each crest 21 has a plurality of bent ends 23.

The bent ends 23 protrude left and right while being sequentially alternated along the crests 21, and protrude back and forth while being sequentially alternated in a direction perpendicular to the crests 21 (that is, in the direction along which the crests and valleys are repeatedly formed). Accordingly, a fluid passing through corresponding bent ends 23 may become turbulence flow.

However, as described above, the turbulator 20 according to the related art cannot be installed in such a manner that the fluid flows in a direction along which the crests 21 and the valleys 22 are repeatedly formed, but installed in such a manner that the fluid flows along the crest (or the valley).

In other words, due to the structural limitation of a molding apparatus (i.e., the width of the molding apparatus), the turbulator 20 is formed lengthwise only in a direction along which the crest 21 and the valley 22 are repeatedly formed, and cannot be molded in a direction perpendicular to the direction along which the crest 21 and the valley 22 are repeatedly formed. In addition, when the turbulator 20 having the structure is installed in such a manner that the flow direction of the fluid becomes the direction along which the crest 21 and the valley 22 are repeatedly formed, the fluid resistance is excessively increased, so that the turbulator 20 may not be actually used in an oil cooler for a large-scale hydraulic apparatus.

Therefore, the turbulator 20 must be installed in a direction perpendicular to the direction along which the crest 21 and the valley 22 are repeatedly formed. However, in this case, the turbulence performance of the fluid may be degraded.

In addition, since the turbulator 20 cannot be installed in the direction perpendicular to the direction along which the crest and the valley are repeatedly formed, the turbulator is not integrally formed, but must be provided in an assembled type in which the turbulator 20 is divided into a plurality of sections and the sections are sequentially coupled with each other in the flow direction of the fluid. Therefore, the work effort to install the turbulator 20 is increased, so that the workability may be degraded, and the performance of a heat exchanger may be degraded.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a heat exchanger and a turbulator for the heat exchanger, in which a heat exchanger is integrally manufactured in a novel structure with a desirable size, so that the productivity can be improved and the flow resistance of the fluid can be minimized.

In order to accomplish the above objects, according to one aspect of the present invention, there is provided a heat exchanger including a plurality of heat exchange plates stacked on each other while being spaced apart from each other, and a turbulator interposed between the heat exchange plates. The turbulator has a plurality of crests and a plurality of valleys, which are repeatedly formed along a flow direction of a fluid while being integrally provided with each other, and each crest has a plurality of bent ends, which are formed on each crest and bent inwardly while being repeatedly alternated. The tabulator has a through hole defined by the bent ends in a direction along which the crest and the valley are repeatedly formed, so that the fluid passes through the through hole.

In this case, the bent ends formed on the each crest of the turbulator are inwardly bent in a state that the bent ends are inclined in the flow direction of the fluid, and the through hole to allow the fluid to flow therethrough is defined by the bent ends.

In addition, each bent end is inclined at an angle in a range of 20° to 45°.

According to another aspect of the present invention, there is provided a turbulator for a heat exchanger, which includes a plurality of crests and a plurality of valleys that are repeatedly formed, and a plurality of bent ends formed on front and rear surfaces of each crest and inwardly bent while being repeatedly alternated in a direction along which the crest and the valley are repeatedly formed. A portion of each bent end is inclined left or right to form a through hole perforated in the direction along which the crest and the valley are repeatedly formed so that the fluid passes through the through hole.

In this case, each bent end is inclined at an angle in a range of 20° to 45°.

In addition, the bent ends formed on each crest are inclined in symmetry to each other in a direction along which each crest is repeatedly formed, and the direction is a flow direction of the fluid.

In addition, when viewed in the direction serving a flow direction of a fluid along which the crest and the valley are repeatedly formed, the bent ends provided at the left sides are inclined in symmetry to the bent ends provided at the right sides.

Further, the crests and the valleys are inclined about an introduction direction of a flow which is a flow direction of the fluid. In this case, the crests and the valleys are inclined at an angle in a range of 10° to 30°, and each bent end is inclined at an angle in a range of about 20° to 45°.

As described above, since the turbulator for the heat exchanger according to the present invention can be arranged in a direction along which the crest and the valley are repeatedly formed along the flow direction of a fluid, the turbulator can be integrally manufactured regardless of a desirable length. Accordingly, the assembling processes of installing the turbulator can be reduced, so that the workability can be improved.

In particular, according to the turbulator for the heat exchanger of the present invention, a fluid can be more turbulated due to inclined bent ends as compared with that of a installation structure for heat radiation according to the related art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a turbulator for a typical heat exchanger according to the related art;

FIG. 2 is an exploded perspective view showing the structure of a heat exchanger according to an exemplary embodiment of the present invention;

FIG. 3 is a plan view showing the structure of the heat exchanger according to an exemplary embodiment of the present invention;

FIG. 4 is a side sectional view showing the structure of the heat exchanger according to an exemplary embodiment of the present invention;

FIG. 5 is a plan view showing another example of the structure of a heat exchanger according to an exemplary embodiment of the present invention;

FIG. 6 is a side sectional view showing another example of the structure of a heat exchanger according to an exemplary embodiment of the present invention;

FIG. 7 is an exploded perspective view showing a main component in the structure of a turbulator for the heat exchanger according to an exemplary embodiment of the present invention;

FIG. 8 is a plan view showing the turbulator for a heat exchanger according to another embodiment of the invention;

FIG. 9 is a plan view showing a turbulator for a heat exchanger according to still another embodiment of the present invention;

FIG. 10 is a plan view showing a turbulator for a heat exchanger according to still another embodiment of the present invention; and

FIGS. 11 to 14 are views showing a method for molding the turbulator according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, a heat exchanger and a turbulator for the heat exchanger according to an exemplary embodiment of the present invention will be described with reference to FIGS. 2 to 14.

The heat exchanger according to the exemplary embodiment of the present invention includes a heat exchange plate 100 and a turbulator 200 as shown in FIG. 2.

The heat exchange plate 100 performs heat exchange with a fluid and guides the flow of the fluids. A plurality of heat exchange plates 100 are provided, and stacked on each other while being spaced apart from each other.

In addition, partition bars 110 are interposed between the heat exchange plates 100 corresponding to both side ends of the heat exchange plates 100 when viewed in the flow direction of a fluid, thereby uniformly maintaining the distance between the heat exchange plates 100 while defining the fluid passage.

In this case, two or three partition bars 110 may be provided according to the number of the fluid passages between the heat exchange plates 100. In other words, as shown in FIGS. 3 and 4, if one fluid passage exists between the heat exchange plates 100, the partition bars 110 are provided at both sides (top and bottom sides of the drawings) of each heat exchange plate 100, respectively. As shown in FIGS. 5 and 6, if two fluid passages exist between the heat exchange plates 100, one partition bar 110 is additionally interposed between the fluid passages, and the turbulator 200 is provided between the partition bars 110.

The turbulator 200 is provided between the heat exchange plates 100 while turbulating a fluid passing between the heat exchange plates 100, thereby improving a heat exchange effect.

Hereinafter, the structure of the turbulator 200 will be described in more detail.

The turbulator 200 has a structure in which a plurality of crests 210 and a plurality of valleys 220 are repeated, and each crest 210 includes a plurality of bent ends 230 and a plurality of through holes 240.

In this case, the bent ends 230 are formed by bending a portion of the crest 210 downwardly through a lancing process. When viewed in a direction along which the crest 210 and the valley 220 are repeatedly formed, the bent ends 230 are alternately repeated on the front and rear surfaces of each crest 210 while being inwardly bent and partially inclined left and right.

Therefore, each crest 210 has the through hole 240 formed therein by the inclined bent ends 230 so that a fluid can flow through the through hole 240. The through hole 240 is perforated in the direction along which the crest 210 and the valley 220 are repeatedly formed.

The above structure is shown in FIG. 7.

In particular, an embodiment of the present invention suggests that an inclination angle a of each bent end 230 is determined in the range of about 20° to 45°. The bending direction of each bent end 230 is inclined at an angle of 20° to 45° about a direction along which the crest 210 is formed. This is shown in an exploded view of FIG. 3.

The limitation to the range of the inclination angle α minimizes the flow resistance of a fluid while increasing turbulence. In addition, the limitation allows desirable molding.

If the inclination angle α of the bent end 230 is 20° or less, the flow of a fluid is significantly interrupted by the front and rear surfaces of the related crest 210, so that the resistance according to the fluid flow may be increased. If the inclination angle of the bent end 230 is 45° or more, the resistance according to the fluid flow may be increased similarly to the case of the inclination angle of 20° or less, and the molding of the bent end 230 may be difficult.

Meanwhile, the embodiment of the present invention suggests that the turbulator 200 is not separately provided between the heat exchange plates 100, but integrally provided between the heat exchange plates 100 in the flow direction of a fluid.

To this end, as shown in FIGS. 3 and 5, the turbulator 200 according to the embodiment of the present invention is provided between the heat exchange plates 100 in such a manner that the crests 210 and the valleys 220 are repeatedly arranged in the flow direction of a fluid.

In other words, molding is performed in the direction along which the crest 210 and the valley 220 are repeatedly formed in the case of a roll process or other molding processes. Accordingly, the turbulator 200 can be integrally manufactured by allowing a fluid to flow in the direction along which the crest 210 and the valley 220 are repeatedly formed.

In particular, since the turbulator 200 can be integrally manufactured, the turbulator 200 can be installed between the heat exchange plates 100 through one work. Accordingly, the working time can be saved.

Hereinafter, a heat exchange process by the turbulator for the heat exchanger according to an exemplary embodiment of the present invention will be described.

First, an external fluid introduced through an inlet of the heat exchanger passes between the heat exchange plates 100.

In this case, the fluid passes through the turbulator 200 interposed between the heat exchange plates 100. The fluid is turbulated while passing through the turbulator 200, so that the fluid can more smoothly exchange heat with the heat exchange plate 100.

In other words, the fluid is guided by the bent end 230 formed at each crest 210 of the turbulator 200, so that the fluid passes through the through hole 240 formed by obliquely molding the bent ends 230. The fluid is turblated while flowing along the through hole 240 to exchange heat with the heat exchange plate.

Next, the fluid, which has passed through the turbulator 200 between the heat exchange plates 100 through a series of processes, is discharged out of the heat exchanger through an outlet of the heat exchanger.

Meanwhile, the shape of the turbulator 200 according to the present invention is not limited to a shape in which the bent ends 230 are inclined in the same direction.

For example, as shown in FIG. 8, the inclined directions of the bent ends 230 of the crests 230 may be sequentially symmetrical to each other in the direction along which the crests 230 are repeatedly formed, which is the flow direction of a fluid.

In other words, if the bent ends 230 of the crests 210 in an initial row are inclined left toward the rear portion of the turbulator, the bent ends 230 of the crest 210 in the next row may be inclined right toward the rear portion of the turbulator.

Accordingly, the turbulation of the fluid can be more improved.

In addition, as shown in FIG. 9, when viewed in the direction along which the crests 210 and the valleys 220 are repeatedly formed, that is, when viewed in the flow direction of the fluid, the bent ends 230 provided at the left sides are inclined symmetrically to the bent ends 230 provided at the right sides.

In other words, if the bent ends 230 formed at the left side of the turbulator 200 are inclined left toward the rear portion of the turbulator 200, the bent ends 230 formed at the right side of the turbulator 200 are inclined right toward the rear portion of the turbulator 200.

Accordingly, the turbulation of the fluid can be more improved.

In addition, as shown in FIG. 10, the turbulator 200 according to the present invention may be configured in such a manner that the crests 210 and the valleys 220 are inclined about the introduction direction of the fluid, that is, the flow direction of the fluid.

In other words, due to the additional inclination structure of the crests 210 and the valleys 220, the through hole 240 has a double inclined structure including the above inclination structure and the inclination structure of the bent ends 230. Accordingly, the turbulization of the fluid can be more improved.

In this case, preferably, the inclination angle of the crests 210 and the valleys 220 is in the range of about 10° to 30°, and the inclination angle of the bent ends 230 is in the range of about 20° to 45°.

If the inclination angle of each crest 210 or each valley 220 is less than 10°, the improvement of the turbulation according to the double inclination structure may be extremely slightly represented. If the inclination angle of each crest 210 is greater than 30°, the fluid may not smoothly flow due to the extreme inclination of the through hole 240. Accordingly, the inclination of the crest 210, the valley 220, and the bent end 230 are preferably determined in the above range.

Meanwhile, FIGS. 11 and 12 show one molding example of the turbulator 200 according to the present invention.

In other words, as shown in FIG. 11, the turbulator 200 may be molded through a typical scheme in which a tool 300 to mold the bent end 230 is installed perpendicularly to an introduction direction of a raw material.

In order to incline the crests 210 and the valleys 220 constituting the turbulator 200 in the introduction direction of a fluid, that is, in the flow direction of the fluid as shown in FIG. 10, the tool 300 to mold the bent end 230 may be obliquely installed as shown in FIG. 12.

In addition, in order to incline the forward direction of the turbulator 200 which has passed through the tool 300, the turbulator 200 may be molded in the arrangement structure shown in FIGS. 13 and 14.

As described above, the turbulator 200 according to the present invention can be molded through various schemes.

Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. 

1. A heat exchanger comprising: a plurality of heat exchange plates stacked on each other while being spaced apart from each other; and a turbulator interposed between the heat exchange plates, the turbulator having a plurality of crests and a plurality of valleys, which are repeatedly formed along a flow direction of a fluid while being integrally provided with each other, each crest having a plurality of bent ends, which are formed on each crest and bent inwardly while being repeatedly alternated, and the tabulator having a through hole defined by the bent ends in a direction along which the crest and the valley are repeatedly formed, so that the fluid passes through the through hole.
 2. The heat exchanger of claim 1, wherein the bent ends formed on the each crest of the turbulator are inwardly bent in a state that the bent ends are inclined in the flow direction of the fluid, and the through hole to allow the fluid to flow therethrough is defined by the bent ends.
 3. The heat exchanger of claim 2, wherein each bent end is inclined at an angle in a range of 20° to 45°.
 4. A turbulator for a heat exchanger, the turbulator comprising: a plurality of crests and a plurality of valleys that are repeatedly formed; and a plurality of bent ends formed on front and rear surfaces of each crest and inwardly bent while being repeatedly alternated in a direction along which the crest and the valley are repeatedly formed, wherein a portion of each bent end is inclined left or right to form a through hole perforated in the direction along which the crest and the valley are repeatedly formed so that the fluid passes through the through hole.
 5. The turbulator of claim 4, wherein each bent end is inclined at an angle in a range of 20° to 45°.
 6. The turbulator of claim 4, wherein the bent ends formed on each crest are inclined in symmetry to each other in a direction along which each crest is repeatedly formed, and the direction is a flow direction of the fluid.
 7. The turbulator of claim 4, wherein, when viewed in the direction serving a flow direction of a fluid along which the crest and the valley are repeatedly formed, the bent ends provided at the left sides are inclined in symmetry to the bent ends provided at the right sides.
 8. The turbulator of claim 4, wherein the crests and the valleys are inclined about an introduction direction of a flow which is a flow direction of the fluid.
 9. The turbulator of claim 8, wherein the crests and the valleys are inclined at an angle in a range of 10° to 30°, and each bent end is inclined at an angle in a range of about 20° to 45°. 